0638160600

Battery Powered Crimping Tool BATTERY POWERED CRIMPING TOOL Operation Manual Order No. 63816-0200 (110 V) Order No. 63816-0250 (220 V) Order No: TM-638160200 Revision: F Release Date: 12.06-07 Revision Date: 04-18-14 UNCONTROLLED COPY Page 1 of 36 Battery Powered Crimping Tool Table of Contents BATTERY POWERED CRIMPING TOOL ........................................................................................................................1 Safety Warnings and Information .....................................................................................................................................3 SECTION 1 ......................................................................................................................................................................7 Description ................................................................................................................................................................................... 7 1.1. Features....................................................................................................................................................................... 7 1.2. Technical Specifications .............................................................................................................................................. 8 1.3 Delivery Check............................................................................................................................................................. 8 SECTION 2 ......................................................................................................................................................................9 Power Crimp Heads and Adapters............................................................................................................................................... 9 2.1 Comparison Chart - Hand and Power Crimp Tools.................................................................................................... 10 2.2 63816-0600 Power Crimp Adapter for Type 4A Hand Crimp Tools ........................................................................... 11 2.3 63816-0300 Power Crimp Head for Type 2C and 4C Hand Crimp Tools .................................................................. 13 2.4 63816-0800 Power Crimp Head for Type 4D Hand Crimp Tools ............................................................................... 15 2.5 63816-1600 Power Crimp Head for Type 4E Hand Crimp Tools ............................................................................... 18 2.6 63816-0900 Power Adapter for Type AT Air Crimp Heads ........................................................................................ 21 SECTION 3 .................................................................................................................................................................... 23 Set-Up and Adjustments ............................................................................................................................................................ 23 3.1 Set-Up........................................................................................................................................................................ 24 3.2 Operation ................................................................................................................................................................... 25 3.3 Preventive Instructions .............................................................................................................................................. 26 SECTION 4 .................................................................................................................................................................... 27 General Terminal Specifications and Crimping Operation ......................................................................................................... 27 4.1 Scope......................................................................................................................................................................... 28 4.2 Crimping Terminals.................................................................................................................................................... 28 SECTION 5 .................................................................................................................................................................... 29 Preventive Maintenance ............................................................................................................................................................ 29 5.1 Periodic Cleaning....................................................................................................................................................... 30 5.2 Battery and Charging Unit.......................................................................................................................................... 31 5.3 Disposal ..................................................................................................................................................................... 32 5.4 Warranty .................................................................................................................................................................... 32 SECTION 6 .................................................................................................................................................................... 33 6.1 6.2 Parts List and Assembly Drawings ............................................................................................................................ 34 Troubleshooting ........................................................................................................................................................ 36 Order No: TM-638160200 Revision: F Release Date: 12.06-07 Revision Date: 04-18-14 UNCONTROLLED COPY Page 2 of 36 Battery Powered Crimping Tool Safety Warnings and Information Read and understand all of the instructions and safety information in this manual before operating or servicing this tool. Keep this manual available when using this tool. Replacement manuals are available for download at no charge at www.molex.com. SAFETY ALERT SYMBOL This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word provides information for preventing or avoiding the hazard. DANGER: DANGER Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury. WARNING: WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events that could lead to personal injury. WARNING Always wear proper eye protection when Operating or servicing this tool. Failure to wear eye protection could result in serious eye injury from flying debris or hydraulic oil. WARNING WARNING Always wear proper ear protection when Operating or servicing this tool. WARNING Electric shock hazard: Never wear clothing or jewelery that is loose or That could potentially get caught in this tool. Failure to observe this warning could result in Severe Injury or death. WARNING This tool is not insulated. When using this unit near energized electrical lines, use proper personal protective equipment. Failure to observe this warning could result in severe injury or death WARNING Pinch points: Never operate, service, install, or adjust this tool without proper instruction and without first reading and understanding the instructions in this manual and all applicable manuals. Order No: TM-638160200 Revision: F Release Date: 12.06-07 Revision Date: 04-18-14 Keep hands away from the crimping head when crimping. Failure to observe this warning could result In severe injury or death. UNCONTROLLED COPY Page 3 of 36 Battery Powered Crimping Tool WARNING WARNING Do not use compressed air to clean this tool. The forces created by compressed air can force debris into the tool. Do not use solvents or flammable liquids to clean the crimping tool. Solvents or flammable liquids could ignite and cause serious injury or property damage. Failure to observe these precautions may result in injury or property damage. WARNING WARNING Inspect tool and dies before use. Replace any worn or damaged parts. A damaged or improperly assembled tool can break and strike someone nearby. Do not dispose of the battery in a fire. It will vent fumes and may explode. Failure to observe this warning could result in severe injury from harmful fumes or burns from flying debris Failure to observe this warning could result in severe injury or death. CAUTION Do not operate the tool without the dies. Damage to the ram or crimping head can result. Do not operate with the crimping head open. Damage to the ram or seals can result. This tool is not designed for continuous use. After 100 crimping cycles, allow the crimping tool to cool down for 15 minutes. Do not place the tool in a vise. The crimping tool is designed for hand-held operation only. This tool may be used in damp or wet environments; however, we recommend air-drying the tool before use if it becomes soaked. Use this tool for the manufacturer’s intended purpose only. Failure to observe these precautions may result in injury or property damage CAUTION Do not allow anything to contact the battery’s terminals. Do not immerse the battery in liquid. Liquid may create a short circuit and damage the battery. If the battery is immersed, contact your service center for proper handling. Do not place the battery into a pocket, tool pouch, or tool box with conductive objects. Conductive objects may create a short circuit and damage the battery. Do not place a battery on moist ground or grass. Moisture may create a short circuit and damage the battery. Failure to observe these precautions may result in injury or property damage. CAUTION Do not store the battery at more than 60 °C (140 °F). Damage to the battery can result. Do not use another manufacturer’s charger. Other manufacturers’ chargers may overcharge and damage the battery. Do not attempt to open the battery. It contains no user-serviceable parts. Failure to observe these precautions may result in injury or property damage. CAUTION Never perform any service or maintenance other than as described in this manual. Never modify, alter or misuse the equipment Molex crimp specifications are valid only when used with Molex terminals, applicators and tooling. Failure to observe this precaution may result in injury and property damage. Order No: TM-638160200 Revision: F Release Date: 12.06-07 Revision Date: 04-18-14 UNCONTROLLED COPY Page 4 of 36 Battery Powered Crimping Tool Tooling Technical Assistance Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments. This support can be obtained by calling either of the two numbers listed below and asking for the Molex Tooling Group. Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global). This assistance is limited to the operation and set-up of a customer’s Molex tool. Questions with regard to Molex connector products or how to identify the proper tooling and/ or tooling documentation should be directed to your local Molex personnel or Customer Service Representative. When calling for service on this tool, a copy of the Tooling Manual and Specific Application Tooling Specification (ATS) Sheet should be present and a person that is familiar with this tool should be present. Be sure the following information is supplied: 1. 2. 3. 4. 5. 6. 7. 8. Customer name Customer address Person to contact such as (name, title, e-mail, and telephone number Power tool order number (Lease number also if applicable) Serial number (Lease number also if applicable) Molex Connector product order number Urgency of request Nature of problem Molex Application Tooling Group 2200 Wellington Court Lisle, IL 60532, USA Tel: +1 (630) 969-4550 Fax:+1 (630) 505-0049 Visit our Web site at http://www.molex.com Order No: TM-638160200 Revision: F Release Date: 12.06-07 Revision Date: 04-18-14 UNCONTROLLED COPY Page 5 of 36 Battery Powered Crimping Tool Table of Contents SECTIONS 1. General Description 2. Power Crimp Heads and Adapters 3. Set-up and Adjustments 4. Terminal Specifications and Crimping Operation 5. Preventive Maintenance 6. Parts List, Assembly Drawing, and Troubleshooting Order No: TM-638160200 Revision: F Release Date: 12.06-07 Revision Date: 04-18-14 UNCONTROLLED COPY Page 6 of 36 Battery Powered Crimping Tool SECTION 1 Principal Mechanical Parts of the 63816-0200 (110 V) and the 63816-0250 (220 V) Battery Powered Tool. Battery charger not shown. LOCKING PINS (2) CRIMPING HEAD ADAPTER RETRACTOR SLIDE TRIGGER UNLOCKING SWITCH RECHARGEABLE (NiCad 9.6V) BATTERY Figure 1-1 Description The Molex Battery Powered Tool is designed to crimp terminals with the use of interchangeable modular crimp heads or power crimp heads, and tool kits. This tool has an automatic retractable system which returns the crimping adapter along with the crimping dies to the starting position when the maximum force is reached. It is equipped with a special brake that will stop the forward motion of the crimping dies when the trigger is released. The crimping head can be rotated 360° for better access in difficult working situations. 1.1. Features Crimps a wide range of products with interchangeable modular crimp heads or power crimp heads, and tool kits, which reduce the overall cost and provide production flexibility. Modular crimp heads or power crimp head and dies are easily and quickly interchanged to reduce production down time. Complete portable system that allows tool to be moved and stored easily. Order No: TM-638160200 Revision: F Release Date: 12.06-07 Revision Date: 04-18-14 UNCONTROLLED COPY Page 7 of 36 Battery Powered Crimping Tool 1.2. Technical Specifications Dimensions (with battery) Length Width Depth Unpacked Weight 292.1mm (11.50”) 76.2mm (3.00“) 50.8mm (2.00“) 1.50kg (3.31lbs) Production Rate 250 cycles per hour maximum, depending on operator skill and tool kit installed. Battery Voltage 9.6V Capacity 1.3 Ah Charging Time Approximately 40 minutes, about 15 minutes with fast-charger Crimps/battery-charge 150 at 10mm2 Operating Parameters Maximum Force 15kN (1.7 tonne-force) Cycle Time 2.0 seconds Stroke Length 9.00mm (.354”) Ambient Temperature -20oC to +40oC Sound Level 75dB (A) in a distance of 1.0m Vibrations